machine

How to rollform steel studs and tracks

Industrial roll former used to manufacture stud and trackOne of the most common uses for a roll forming machine is the manufacturing of steel studs and tracks.  Steel framing is commonly used in the commercial high-rise building and construction industry.  Lightweight and easy to assemble this alternative to standard wooden stick framing has gained popularity in the commercial sector.  So how are these common low cost parts manufactured.

7 steps to rollforming studs and tracks

There are 7 basic steps to foll forming studs and track.  Most industrial machines can manufacture all common sizes and profiles used for common drywall construction. The typical configuration for producing high volume parts includes 7 major systems.  Each performs a unique function through the forming process.  From preparation of the metal for bending to cut outs and holes needed for running wires and plumping on the job site.

1) Uncoiler

The uncoiler holds the master coil and feeds in to the line.  Alignment is critical here as any deviation will be amplified through the rolling process causing defects in the final product.

2) Flattener

The flattener add another step to pre-forming quality control.  Having a consistent material thickness as it feeds in to the rollformer is also critical to producing a high quality part.

3) Lubricator

The lubrication unit ensures the metal is easily bent as it passes through each roll stand.  Without this the metal would bind and rip apart as the rolls form the profile of the stud or track.

4) Pre-punch press

Pre-punching is a custom function and is where the holes and notches are made in the stud.  These are located in a common location to allow for wiring and plumping to easily pass through the studs.

5) Mill

The mill is where the forming action takes place.  The roll tooling bends and shapes the sheet metal in to the desired stud or track profile.

7) Cut-off press

The final steps is to cut off to the desired length either a stud or track.  Lengths can vary to fill an order size.

For more information see our stud and track rollforming machine lines.

 

Purlin

One of the more common building and construction materials manufactured by cold forming steel is the purlin or girt.  This structural steel (versatile) component is an essential part of any building project.   the roll forming machine is a perfect match for purlin production.

Production line considerations for making purlins

C/Z Purlin roll formerBy their very nature purlins are straight uniform designs.  The common profiles include C, Z and Sigma and include common hole and notch placement.  As with many sheet metal materials used in the building industry having this type of uniformity and consistency allows manufacturers to produce high volume low cost products.

Considerations for roll forming purlins

The cold forming of any heavy gauge material such as that used in the fabrication of purlins requires specific machinery.  The rollformer is no exception.  As sheet metal material thickness and hardness increases so do the requirements of all components and auxiliary equipment attached to the forming mill.

Design considerations

  1. Uncoiler design
  2. Uncoiler bracking
  3. In-feed guide system
  4. Mill base and support system
  5. Roll tolling
  6. Tooling stands
  7. Hole punching systems
  8. Cut-off press

Each of these areas within the forming process is critical when manufacturing C/Z purlins.   Minimizing the quality of any of these will result in poor quality product and high re-work costs.

For more information on our purlin roll formers contact us today.

 

 

Duplex mill offers more than increased speed for panel lines

One simple way to increase the output of your roll forming line is to add a second mill.  This ‘duplexing‘ is a common practice for many production process however, there is more options than throughput for a rollformer panel line.

Sheet metal panel roll forming equipment line.

Duplex roll forming machine

Duplex roll forming equipment

With two cold forming mills installed next to each other a number of efficiencies begin to appear.  With a few changes to the infeed steel coil handling equipment (uncoilers) and the roll tooling assemblies or rafted / cassette tooling a manufacturer can service a wide range of clients.

Benefits to having a duplex roll forming machine for panel production

  1. Increased production rates
  2. Panel profile (shape) flexibility
  3. Reduced labor split over 2 lines
  4. One material handling system (uncoiler) on infeed
  5. Easier sheet metal panel stacking equipment

There are numerous ways to increase your bottom line with a duplex rollforming machine.  For more information on these special metal forming lines contact us today.

New corrugated steel panel roll forming machines

Corrugated Panel Roll Forming Machine

Corrugated Panel Roll Forming Machine

Designed and engineered to manufacture common sizes of corrugated roofing or siding panels with minimal change-over.  This machine is a workhorse in the steel fabrication industry.  Used all over the world this machine is designed to produce steel panels 24/7.

Corrugated Roll Forming Machine

Corrugated Metal Panels

The most common sizes manufactured are shown below.  This sizes can often all be formed on the same mill.  Simple change out of the roll tooling either by stand or on racks can be done.  This flexibility allows for virtually all sizes to be made.

Common Corrugated Panel Sizes

  • 1.25 inch by .25 inch
  • 2.5 inch by .5 inch
  • 2.67 inch by .75 inch
  • 2.67 inch by 7/8 inch

Rollformer Line Configuration

The standard roll former line configuration includes an uncoiler, flattener, lubrication system, rolling mill and cut-off.  The number of roll tooling stands required for this type of steel profile is 20 to 30 stands or more.  Unlike other profile shapes the bending of steel in to this shape requires both a greater number of rolls and system length.

Optional Equipment

Typical options for a corrugated roll former include the following.

  • Stacker
  • Bundler
  • Multi-head Uncoiler

Companies using roll forming machines for manufacturing steel panels

  • Vicwest
  • Metal Sales
  • Fabral
  • Central States Manufacturing

Leadership

Manufacturing leading rollforming machinery for the steel fabrication industries around the world

Innovation

Developing new technologies and automation focused on delivering leading edge metal forming equipment

Design

Designing equipment to automate and process steel formed products more effectively and preciously